Factors that affect PCB manufacturing cost

Before we dive into specific PCB fabricators, it’s important to understand the various factors that can impact the overall cost of PCB manufacturing:

• Board size: Larger PCBs will generally cost more than smaller ones. PCB size is often measured in square inches.

• Number of layers: More complex designs with a higher layer count (4+ layers) will be pricier than simple 1-2 layer boards. Each additional copper layer adds to the manufacturing cost.

• Quantity: Higher volumes usually translate to a lower per-unit cost. But be aware of minimum order quantities (MOQs).

• Turn time: Faster production times come with a premium price. If you have flexibility on your timeline, opting for a standard lead time can reduce costs.

• Special requirements: Things like tight tolerances, unique materials, controlled impedance, blind/buried vias, etc. can all add to the cost.

Here’s a general overview of how these factors impact relative PCB cost:

Factor	Low Cost	High Cost
Board size	Small	Large
# of layers	1-2	4+
Quantity	High volume	Low volume
Turn time	Standard (1-2 weeks)	Expedited (1-5 days)
Special requirements	Standard specs	Tight tolerances, special materials, etc.

Online PCB fabrication services

One of the best ways to get cheap PCBs manufactured is by using an online PCB fabrication service. These companies specialize in quick-turn, low-volume PCB orders. You simply upload your PCB design files, choose your specifications, and receive a quote instantly.

Here are some of the most popular online PCB fabricators known for affordable pricing:

1. JLCPCB

JLCPCB is one of the largest online PCB manufacturers, known for their competitive prices and excellent quality. They offer a variety of low-cost options, including:

• $2 for 5pcs 1-2 layer PCBs less than 100x100mm
• Discounts for higher quantities (up to 30% off 100+ pcs)
• Wide selection of PCB Colors at no extra cost
• Affordable PCB Assembly services

With 16 strategically located international delivery centers, shipping is fast and inexpensive as well. Lead times range from 24 hours to 5 days depending on requirements.

2. PCBWay

PCBWay is another well-known online PCB manufacturer that offers low-cost, high-quality PCBs. Some key benefits include:

• $5 for 10pcs 1-2 layer PCBs less than 100x100mm
• Student discounts and free PCBs for student projects
• Extensive online knowledge base and engineering support
• Affordable PCB assembly and 3D printing services

PCBWay also offers a handy online quote calculator to get an instant price based on your specific needs. Standard lead time is 2-3 days for PCB fabrication.

3. Seeed Studio Fusion PCB

Seeed Studio is an electronics manufacturer that offers a cheap PCB fabrication service called Fusion PCB. Key features include:

• $4.90 for 10pcs 1-2 layer PCBs less than 100x100mm
• Wide selection of PCB colors, surface finishes, and solder masks
• Integration with popular EDA tools like Altium, Eagle, and KiCad
• Open parts library to aid component selection for assembly

The standard lead time from Seeed Studio Fusion PCB is 7-10 days, which is a bit longer than some competitors. But this can be a good option for hacking projects where super speedy turnaround isn’t critical.

Domestic and regional PCB Suppliers

While the rock-bottom prices are usually found with large overseas manufacturers, there are also benefits to working with domestic or regional PCB suppliers. These include faster shipping times, easier communication, and the ability to build a relationship with your supplier.

Some notable regional low-cost PCB fabricators include:

United States

• OSH Park – Known for their signature purple PCBs. Offers a “Flex Fabrication – 2 Layer” service starting at $10 for 3pcs.
• Bay Area Circuits – Quick-turn PCB shop located in Silicon Valley. Specializes in low-volume prototypes and production runs.

Europe

• Eurocircuits – Netherlands-based PCB supplier. Offers full prototype service with 1-8 layer boards starting at €39 for 4pcs.
• PCB-Pool – German PCB manufacturer with facilities throughout Europe. Offers 1-16 layer PCBs with no minimum quantity.

India

• PCBPower – Full-service PCB manufacturer based in Delhi. Specializes in single to 6-Layer PCBs with quick lead times.
• CircuitMart – PCB fabricator located in Gujarat. Caters to startups and small businesses with low-volume PCB needs.

While pricing from regional suppliers may not be the absolute lowest, it’s worth getting quotes to compare against the big online fabricators. The tradeoffs in speed, convenience, and supplier relationship can make a domestic option worthwhile.

PCB design considerations for low-cost manufacturing

To get the best possible pricing on PCB manufacturing, it’s important to design your board with manufacturing in mind from the beginning. Here are some design tips to minimize fab costs:

Keep it small and simple

Smaller boards with fewer layers will be cheaper to manufacture. Avoid making the board any larger than it needs to be. Stick to standard shapes like rectangles if possible.

Use common specifications

Choosing standard base materials (like FR-4), soldermasks, and surface finishes will be more economical than specifying specialty materials. Whenever possible, design with standard trace/space widths and drill sizes.

Pay attention to design rules

Each fabricator publishes design rule guidelines that spell out their minimum tolerances and clearances. Violating these will kick your board into a higher cost class – or make it entirely unmanufacturable.

Panelize where possible

If you’re making a small board, consider panelizing it into an array to minimize wasted material. Most fab houses have standard panel sizes which can be more economical. Just be sure to follow the fab’s standards for panelization.

Consider assembling the PCB yourself

If your quantities are low and the design is relatively simple, hand assembling the PCB can be very cost effective. This lets you buy components in cut tape or small reels. For more tips, check out our guide to DIY PCB assembly.

Frequently Asked Questions

What’s the best way to compare pricing between PCB fabricators?

Most online fabs have a quick-quote form where you can input your PCB parameters (size, layers, quantity, etc.) and get an instant quote. You can also usually download a full quote in Excel format with a detailed cost breakdown. Comparing these line-by-line can help identify the most important cost drivers.

Is the cheapest manufacturer always the best option?

Not necessarily. While cost is important, it’s also critical to consider quality, lead time, and technical support. Cheap boards that arrive late or have manufacturing defects will erase those initial savings. Look for a balance of cost, quality, and service.

How can I reduce the cost of PCB assembly?

Simplifying your BOM (bill of materials) is one of the best ways to reduce assembly costs. Using common parts, minimizing the number of unique parts, and selecting easy-to-place packages will streamline the assembly process. It’s also important to follow good DFM (design for manufacturing) practices like orienting all parts in the same direction and avoiding tight clearances.

What are some common “gotchas” in low-cost PCB manufacturing?

One big one is unexpected tooling charges. Lower-cost fabs often amortize the cost of making stencils, jigs, and test fixtures across the production run. If your design has a lot of custom requirements, these can add up quickly.

Another potential issue is inconsistent quality. Cheaper suppliers may cut corners on inspection and testing. It’s important to communicate your quality expectations clearly up-front and verify that your fab has a robust quality control process in place.

What file formats are required to get PCBs manufactured?

Most PCB fabricators will ask for Gerber files, which are the industry standard for PCB designs. You’ll need to generate Gerber files for each copper layer, solder masks, silkscreens, and drill layers. The fab will also typically need a centroid file (aka pick-and-place file) with all the component locations and orientations.

Be sure to double check your design in a Gerber viewer before submitting for manufacturing. This can catch common issues like incorrect apertures, acid traps, and missing solder mask clearances.

Conclusion

With the global ecosystem of PCB suppliers available today, getting boards manufactured on a budget is very doable. Online manufacturers like JLCPCB, PCBWay, and Seeed Studio Fusion PCB are great options for affordable, quick-turn PCB fabrication. Regional suppliers can also be cost-competitive, with the added benefits of domestic support and faster shipping.

To get the best possible pricing, remember to design with manufacturing in mind from the beginning. Keep board size down, stick to standard specifications, and be diligent about adhering to design rules and guidelines.

By following the tips and suppliers covered in this guide, you’ll be well on your way to creating high-quality PCBs without breaking the bank. Be sure to get quotes from multiple fabricators, communicate your needs clearly, and test your design early and often. Here’s to successful cheap PCB manufacturing!